Access Panel And Method Of Manufacture

ABSTRACT

An access panel system for providing access into a space behind a surface, such as a ceiling, is disclosed. The system comprises an access panel frame adapted to be disposed in a corresponding opening in the surface, the frame formed from a first sheet of drywall, the access panel frame having an upper frame surface, a lower frame surface and a frame opening, the frame opening formed by milling a section from the sheet of drywall. The system further comprises an access panel formed from a second sheet of drywall, wherein the access panel includes a stepped portion and a flanged portion milled from the second sheet of drywall, and wherein the stepped portion is laterally dimensioned to fit into the frame opening and the flanged portion is adapted to engage the upper frame surface.

BACKGROUND

An access panel, or access door, to provide access from an exteriorspace, such as a room, into an interior space, such as above a drywallceiling or behind a drywall wall, in the room, is known. Often it isdesired that the access panel be generally discreet and concealed,visually blending into the surrounding surface, when viewed from theroom.

An access panel may be one component of what may be referred to as anaccess panel system. The access panel system may also include anassociated frame. The access panel may have a stepped profile,comprising a flanged portion and a stepped portion, the stepped portionbeing preferably centered relative to the flanged portion. The frame mayhave a frame opening corresponding in shape and size to the shape andsize of the stepped portion of the associated access panel, but havingdimensions slightly greater, to permit the frame opening to receive thestepped portion of the access panel to fit into the frame opening.

Typically to install such an access panel system in a ceiling, such as adrywall ceiling, an opening slightly larger than the frame may be cutinto the drywall ceiling. The frame may then be conventionally installedwithin the opening, and a conventional butt joint may be installed inthe gap between the frame and the opening. The access panel may then beplaced in, and supported by, the frame.

An access panel system may be similarly installed in a wall, such as adrywall wall, although a hinged mechanism may be required, as is known.

Certain of such access panels have conventionally been formed ofGlass-Fiber-Reinforced Gypsum (GFRG). As is known, such GFRG panels maytypically be formed in a mold, removed, and then have their edgessanded. This can be a time-consuming process. This process may alsorequire a dedicated mold for each panel size, thereby limiting sizeflexibility and options for such access panels. Panels made of GFRG mayalso have a relatively high moisture content, which may potentially leadto formation of mold, they may be somewhat fragile, and may potentiallysag. As a result, panels made of GFRG have a relatively high materialand production cost.

The present disclosure is provided to address these and other problems.

SUMMARY

It is an object of the present disclosure to provide a method of formingan access panel, and associated frame, such as from sheets ofconventional drywall.

It is a further object of the present disclosure to provide an accesspanel, and associated frame, according to such a method.

This and other objectives and advantages may become apparent from thefollowing description taken in conjunction with the accompanyingFigures.

DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an access panel system, installed in aceiling, in accordance with the present invention;

FIG. 2 is a plan view of the access panel system of FIG. 1 ;

FIG. 3 is a plan view of a frame having a frame opening, as a componentof the access panel of FIG. 1 ;

FIG. 4 is a plan view of an access panel, as a component of the accesspanel system of FIG. 1 ;

FIG. 5 is a sectional view of the access panel of FIG. 4 ;

FIG. 5 a is a detailed view of the access panel of FIG. 5 ;

FIGS. 6 and 7 are respective side views of the frame and access panel ofthe present invention;

FIG. 8 is an exploded view of the access panel system of FIG. 1 ;

FIG. 9 is a detailed view of a rounded corner of the access panel ofFIG. 8 ; and

FIG. 10 is a detailed view of a rounded inner corner of the frame ofFIG. 8 .

DESCRIPTION OF THE PREFERRED EMBODIMENT

While this invention is susceptible of embodiments in many differentforms, there will be described herein in detail, a specific embodimentthereof, with the understanding that the present disclosure is to beconsidered an exemplification of the principles of the invention and isnot intended to limit the invention to the specific embodimentillustrated.

The present method may utilize a Flextos Supercut CNC Automated Millingand Sawing Table (the milling machine), manufactured by Flextos GmbH ofRaubling, Germany. The Supercut CNC is available in the US as the HybridCNC/PanelMax ST48, distributed by Grabber Construction Products.Alternative conventional CNC milling machines may also be utilized.

In accordance with the present invention, an access panel system 12 mayinclude an access panel frame 14 having a frame opening 14 a, into whichan access panel 16 may be positioned. The frame 14 may be conventionallyinstalled in an opening of a ceiling 15, such as a conventional drywallceiling. The access panel frame 14 and the access panel 16 maypreferably be formed of conventional drywall. As is known, conventionaldrywall is significantly less expensive than GFRG. A sheet of drywalltypically is formed of a gypsum core, covered on opposing sides by alayer of paper 18—a face paper on a side which is typically theoutwardly facing side (when installed) of the drywall sheet and abacking paper on the opposing side, which side is typically the inwardly(when installed) facing side of the drywall sheet.

The frame 14 may be formed by milling a section from a first sheet ofconventional drywall, preferably a single sheet of ⅝″ (0.63″) thickdrywall, to form the frame opening 14 a within the frame 14. However a½″ design may be made with a ½′ step. The exterior facing edge of theperiphery of the frame 14 may be shaped, such as rounded with a 1/16″radius, to permit a better, more aesthetic finished joint with theceiling 15.

As discussed in greater detail below, the access panel 16 may be formedin a two-step milling process, by milling a second sheet of conventionaldrywall, preferably a single sheet of 1″ thick drywall, to form theaccess panel 16 having a stepped profile comprising a flanged portion 16a, which may be 0.37″ in height, and a stepped portion 16 b, which maybe 0.63″ in height, which corresponds to the thickness of the frame 14). The stepped portion 16 b is adapted to fit through the frame opening14 a, and the flanged portion 16 a is adapted to rest on an uppersurface 14 b of the frame 14, such that the exterior facing (wheninstalled) surface of the frame 4 is substantially flush with theexterior facing surface (when installed) of the access panel 16. Thedimensions of the frame opening 14 a (i.e., the dimension of the sectionremoved from the first sheet of drywall) may be slightly larger than thecorresponding dimensions of the stepped portion 16 b, so as to provide aperipheral gap between the frame opening 14 a and the stepped portion 16b of 0.06″.

Following the milling step, milled edges of the milled drywall,particularly the corners, may be sanded and then sealed, as needed, byan application of a sealant such as a conventional drywall primer, suchas to seal the junction between the drywall interior core and thedrywall paper. But as discussed below, and as illustrated in FIG. 5 a ,the milling bit utilized to form the stepped portion 16 b may preferablyprovide a shaped, preferably rounded, edge, such as a rounded edgehaving a radius of the order of ⅛″- 1/16″, reducing or otherwiseeliminating a tendency for the drywall paper 18 to tear, therebyeliminating the need for the sanding step.

The following is a detailed description of one embodiment ofmanufacturing a version of the access panel 16 to fit into the frameopening 14 a of the associated frame 14. In this embodiment, the accesspanel 16, and the frame opening 14 a of the associated frame 14 aregenerally square. However it is to be understood that other geometries,such as a rectangle or a circle, are contemplated.

According to this embodiment, the flanged portion 16 a of the accesspanel 16 is generally square, having 18.52″ sides, but having generallyrounded corners having a radius of 1.00″. The stepped portion 16 b isalso generally square, having 18.02″ sides, with rounded corners havinga radius of 1.25″.

The frame 14 may be generally square, having 24.08″ sides and squaredcorners. The frame opening 14 a may also be generally square, having18.08″ openings, and rounded corners having a radius of 1.25″. The frame14 has an outer peripheral edge 14 b, which may be shaped, such asrounded, on its interior facing edge, such as to a 1/16″ radius, whichmay help make a better finished join when installed in the ceiling. Theframe 14 has an inner peripheral edge 14 c, which defines the frameopening 14 a. The inner peripheral edge 14 c may also be shaped, such asrounded, on its interior facing edge, such as to a 1/16″ radius.

Utilizing the milling machine, creation of the drywall access panel 16may begin in CAD software.

Drawing the Panel 16 in the CAD Software

According to the present embodiment, a square two-dimensional sketch maybe made (i.e., coordinates may be plotted) measuring 18.52″×18.52″ (thedimension of the flanged portion 16 a of the access panel 16). Note: fordifferent sizes the formula would be blank number 0.95. The sketch maybe filled to create a panel. A second square sketch is made measuring18.02″×18.02″ (the dimension of the stepped portion 16 b of the accesspanel 16). Note: for different sizes the formula would be blank number0.02. The second square sketch may be placed within the large sketch (inthe software), establishing a critical dimension of 0.25″[(18.52″-18.02″)/2] between the outside of the inner square and insideof the larger square. This will maintain even spacing between the innerand outer square. Once aligned, corner chamfers may be added. Thesechamfers may help with rigidity of corner edging, as well as provide amore aesthetic appearance of the access panel 16. A 1.25″ radius may beadded with a conditional formula to apply the radius to each corner ofthe stepped portion 16 b of the panel 16, and a 1.50″ radius may beadded with a conditional formula to apply the radius to each corner ofthe flanged portion 16 a of the panel 16. The inner panel is nowfinished three-dimensionally but must be transposed into atwo-dimensional part for it to be read by the CNC software. The drawingmay be translated into an idw file from an ipt file. The idw file mayallow lines of the door to be exported to a dxf file for interpretationby the CNC software.

Drawing the Frame 14 in the CAD Software

In the instant embodiment, the frame 14 may be three inches greater inoutside dimension than the access panel 16, for the frame 14 to beproperly mounted to ceiling joists and still allow proper operation ofthe access panel 16. See FIG. 3 .

The frame 14 may start with a square that may be approximately sixinches greater than the size of the associated access panel 16.Therefore, an ˜18″×18″ panel preferably requires a ˜24″×24″ frame. Rightnow, there is a panel that is 24 inches×24 inches, a cut needs to bemade within the part in order for the panel to lock into place. A newsketch may be made measuring 18.06″×18.06″. There is roughly a .06″ gapbetween the frame 14 and panel 16 when the product is complete. This isthe difference of the 18.08″ (frame measurement) and 18.02″ (panelmeasurement). The radii within this cut are nearly a 0.010″ differenceto that of the panel in order to maintain consistency and symmetry. Theframe 14 may then be exported into a two-dimensional drawing. Both ofthe dxf files are then uploaded into ESTLcam, the programming softwareof the particular machine. Only one part (one of the access door 16 andthe frame 14) can be programmed at a time since each part is made out ofa different thickness of drywall.

The first part to program may be for the milling is the panel 16. Oneimportant part is creation of the stepped portion 16 b via a specialmilling operation. In the program a 12 mm (0.47″) bit is selected tomill ⅝″ deep of the 1″ thick drywall. The 12 mm bit cuts a 12 mm wideslot. Thus to mill the 1″ thick drywall to form the 18.02″ (across)stepped portion 16 b, the programming must position the 12 mm bit on theinside of the outside measurement of 18.95″. During this operation, theoperator may line up the milling bit to the measurement of a depth of ⅝.Once the bit may be aligned to ⅝″, a zero point may be is selected. Thismay be important to the process of creating a panel 16 because it is howthe next bit to cut will align. Once a zero point is selected anoperator can begin the cut of the stepped portion 16 b. When the bit iscutting, paying proper attention to the cutting is important, formonitoring dust interference and accuracy. Depth gauges may be used tocheck the ⅝″ depth cut within the 1″ shaft liner board.

Once the cut forming the stepped portion has been completed, the routerhead may be removed, and a new router head may be placed with a bithaving a length of 1″ (to cut all of the way through the 1″ sheet ofdrywall). Returning to the program, the 1 inch cutting bit may beselected to cut on the outside of the 18.52″ measurement (so as to leave18.52″ of material). It is important that while programming, the zerohas to stay the same or the dimensions will not line up. It should benoted that manual changing of the bit may be eliminated, such as byutilizing a milling machine having an auto-changing bit or a doublerouter-head.

The bit selected for cutting the stepped portion 16 b must also bedeleted after the spacing of the door is correct. If the first bit isnot deleted from the program, the machine may rerun the first bitgeometric spacing and ruin the cutting, and for multiple door spacingthe first bit may be needed to create the same space between doors butthen may be deleted once the doors are aligned for the second bitprogram.

After the panel 16 is completed, it may be removed. A sanding block maythen be used to ensure burr free paper edges of the door, if needed,however the front is generally finished. A round paint brush may then beused to remove any leftover drywall dust on the edges of the panel.Leaving this dust may interfere with flushness of the panel 16 withinthe frame 14. Once all dust is removed, a square paint brush may be usedto apply the sealant to the cut surface of the stepped portion 14 b.This will minimize or prevent cracking of the drywall and create asmooth durable surface for handling. The access panel 16 is nowfinished.

Milling of the Frame 14

The 1″ drywall is removed, and ⅝″ drywall board is physically uploaded.The frame 14 now needs to be programmed. Within the program, one mayupload the dxf file of the frame 14 and select a 1″ bit to cut theoutside 24″ measurement and inside of the 18.08″ measurement. Thestarting cut of the inside of the frame 14 must begin on a flat contouror cut. If it begins on a corner when it starts and finishes it mayactually hit the completed part during its exit cut. It is importantthat the 18.08 measurement cut is not on the frame side but of theleft-over scrap piece or cut where the access panel will go. Beforebeginning the cut, the operator may preferably check the bit as constantbit changing may create misalignments in the cutting head. The bit mustalso be aligned so that the chamfer where the bit begins is at the topof the cutting head so that when it cuts the frame the paper is cutperfectly. Once the operator has checked the alignment the frame is goodto run. The frame 14 may then be removed, and the drywall sealant may beapplied to the inside and outside cut surface. The sealed access panel16 and frame 14 may then be allowed to dry, such as for an hour or so.

Because the access panel 16 is formed of drywall, it can be painted orotherwise finished, to better visually blend into the surroundingsurface, such as the surrounding ceiling or wall.

It is to be understood that this disclosure is not intended to limit theinvention to any particular form described, but to the contrary, theinvention is intended to include all modifications, alternatives andequivalents falling within the spirit and scope of the invention.

I claim:
 1. An access panel system for providing access into a spacebehind a surface, the system comprising: an access panel frame adaptedto be disposed in a corresponding opening in the surface, the frameformed from a first sheet of drywall, the access panel frame having anupper frame surface, a lower frame surface and a frame opening, theframe opening formed by milling a section from the sheet of drywall; andan access panel formed from a second sheet of drywall, wherein theaccess panel includes a stepped portion and a flanged portion milledfrom the second sheet of drywall, and wherein the stepped portion islaterally dimensioned to fit into the frame opening and the flangedportion is adapted to engage the upper frame surface.
 2. The system ofclaim 1, wherein the stepped portion includes a shaped edge portionabout its periphery.
 3. The system of claim 2, wherein the shaped edgeportion is rounded.
 4. The system of claim 3, wherein the rounded edgeportion has a radius of the order of ⅛″- 1/16″.
 5. The system of claim2, wherein the frame opening includes a shaped edge portion about itsperiphery.
 6. The system of claim 2, wherein the frame includes arounded edge portion about its periphery.
 7. A method of forming anaccess panel, the access panel for providing access through an openinginto a space, the method comprising: providing a first sheet of drywall;providing a milling machine having a bit; utilizing the milling machineto mill the sheet of drywall to create a panel having a flanged portion,the flanged portion having a first peripheral dimension and a steppedportion, the stepped portion having a second peripheral dimension,wherein the first peripheral dimension is greater than the secondperipheral dimension.
 8. The method of claim 7, wherein the step ofmilling to form the stepped portion includes milling an inwardly shapededge about the periphery of the stepped portion.
 9. The method of claim8, wherein the inwardly shaped edge is rounded.
 10. The method of claim9, wherein the sheet of drywall includes a paper coating, and the stepof milling the inwardly shaped edge blends the edge into the papercoating.
 11. The method of claim 10 including: providing a second sheetof drywall; and utilizing the milling machine to mill a section from thesecond sheet of drywall to form a frame opening dimensioned to receivethe stepped portion of the access panel.